A hydroformed expanded spun bonded nonwoven has a first substantially planar surface on one side thereof and a second surface on an opposite side thereof. The second surface includes a plurality of protuberances in a pattern. The hydroformed expanded spun bonded nonwoven web has an average loft of at least about 1.3 times greater than an original average loft of an original unexpanded spun bonded nonwoven web from which the hydroformed expanded spun bonded nonwoven web was created and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed expanded spun bonded nonwoven web includes bicomponent fibers combining a polymer with PLA in a ratio of polymer/PLA within a range of about 20/80 to 80/20.

A hydroformed expanded spun bonded nonwoven has a first substantially planar surface on one side thereof and a second surface on an opposite side thereof. The second surface includes a plurality of protuberances in a pattern. The hydroformed expanded spun bonded nonwoven web has an average loft of at least about 1.3 times greater than an original average loft of an original unexpanded spun bonded nonwoven web from which the hydroformed expanded spun bonded nonwoven web was created and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed expanded spun bonded nonwoven web includes bicomponent fibers combining a polymer with PLA in a ratio of polymer/PLA within a range of about 20/80 to 80/20.

A method of forming a fiber-bound engineered material utilizing carrier screens is provided that imparts an intended characteristic at an intended relative location. Also provided are articles formed of fiber-bound engineered materials manufactured utilizing carrier screens. A fiber layer is placed adjacent at least one carrier screen and entangled with additional fibers in a manner to create a non-uniform engineered material. The lack of uniformity of a fiber-bound engineered material may be accomplished through manipulation of the fibers and/or through fiber binding a scrim. The fiber layer binds with additional fibers through entanglement such that a mechanical connection between the entangled fibers is provided. This entanglement allows the fibers to bind without supplemental adhesives, interlacing, or connections.

A method of forming a fiber-bound engineered material utilizing carrier screens is provided that imparts an intended characteristic at an intended relative location. Also provided are articles formed of fiber-bound engineered materials manufactured utilizing carrier screens. A fiber layer is placed adjacent at least one carrier screen and entangled with additional fibers in a manner to create a non-uniform engineered material. The lack of uniformity of a fiber-bound engineered material may be accomplished through manipulation of the fibers and/or through fiber binding a scrim. The fiber layer binds with additional fibers through entanglement such that a mechanical connection between the entangled fibers is provided. This entanglement allows the fibers to bind without supplemental adhesives, interlacing, or connections.

An absorbent material, such as a non-woven web or a tissue paper, includes continuous filaments and short fibers, the short fibers including natural and/or synthetic fibers or staple fibers. The absorbent material exhibits an absorbency speed of equal to or less than 2 s and a weight loss when washed of equal to or less than 5%. The absorbent material can be incorporated into a wipe.

An absorbent material, such as a non-woven web or a tissue paper, includes continuous filaments and short fibers, the short fibers including natural and/or synthetic fibers or staple fibers. The absorbent material exhibits an absorbency speed of equal to or less than 2 s and a weight loss when washed of equal to or less than 5%. The absorbent material can be incorporated into a wipe.

The present invention relates to a biodegradable non-woven fabric, a method for producing a biodegradable non-woven fabric and a wipe or tissue. The biodegradable non-woven fabric comprises biodegradable fibers and pulp fibers. At least a part of the biodegradable fibers is entangled with each other. At least a part of the pulp fibers is covalently bonded to each other by at least one of the group consisting of a biodegradable binder, a biodegradable wet-strength agent and a biodegradable binder fiber.

A method of forming a sheet material. The method comprises advancing an arrangement comprising a body of fibres and a reinforcing structure, wherein the reinforcing structure comprises splittable fibres. The method further comprises subjecting the arrangement to successive hydroentanglement steps, wherein in each such hydroentanglement step the arrangement is exposed to high pressure jets of liquid over a surface of the arrangement. Subjecting the arrangement to successive hydroentanglement steps causes the fibres of the body of fibres to entangle with each other and causes a mechanical bond to form between the fibres of the body of fibres and the reinforcing structure. The mechanical bond is caused by at least:

some of the fibres of the body of fibres being pushed by the high-pressure jets of liquid into gaps in the reinforcing structure;

at least some of the splittable fibres of the reinforcing structure splitting to form split fibres which reduces the space within the gaps such that the reinforcing structure constricts about fibres of the body of fibres which have been pushed in the gaps; and

at least some of the fibres of the body of fibres entangling with at least some of the split fibres and at least some of the splittable fibres of the reinforcing structure.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.